Current control system for electric welders



April 9, 193% J. v. CAPUTO 9 9 CURRENT GONTROL SYSTEM FOR ELECTRIC WELDERS Filed Dec. 14, 1951 6 Sheets-Sheet 1 .22 v 26 Q 32 J0 XAM INVENTOR Aprfl 9, wa J. v. CAPUTO 1999599492 CURRENT CONTROL SYSTEM FOR ELECTRIC WELDERS Filed Dec. 14, 1931 6 Sheets-Sheet 2 mm fi mm. mmma J. v. CAPUTQ iwwawzr CURRENT COIQTROL SYSTEM FOR ELECTRIC WELDERS Filed De cnl, 1931 6 Sheets-Sheet 3 T E 0 Tu April 9, 1935. J. v. CAPUTO CURRENT CONTROL SYSTEM FOR ELECTRIC WELDERS Filed Dec. 14, 1931 6 Sheets-Sheet 4 INVENTOR Apfii 1935 .1. v. CAPUTO CURRENT CONTROL SYSTEM FOR ELECTRIC WELDERS FiledDc. 14, 1931 6 Sheets-Sheet 5 Ap'zrfl 31%35. J. v. CAPUTO OURRENT CONTROL SYSTEM FOR ELECTRIC WELDERS O Sheets-Sheet 6 Filed Dec. 14, 1951 v WNW QNNI INVENTOR 1 Patented Apr. 9, 1935 UNITED STATE PATENT-OFF ICE CURRENT CONTROL srsrm ron nmc'rnlc wnmnns My invention relates to the art of electric welding and, in particular, to a system ion-automatically controlling .thesupply of currentto an electric welder. Several types of welding machines' operating on the electrical resistance principle are now well known. Among these is the machine embodying an electrode and transformers mounted adjacent thereto for rotation as a unit. It is to such machine that the-present invention is 10 particularly adaptable, although it can also be applied readily to welding apparatus of other types.

It has been known previously that the temperature attained by the edges of a piece'ofskelp .formed into cylindrical shape, upon the passage 15 thereacross ofan electric current, depends upon -the magnitude of the current. The welding current, furthermore, is dependent upon the voltage giving rise to the current and the impedance of the circuit, which is constitutedprincipally by the 20 resistance of the seam between adjacent edges. The resistance across the seam of a formed tube depends upon the pressure exerted between said edges. It has heretofore been the practice to control the welding current manually by varying the 5 voltage applied to the welding circuit, and also by varying the pressure between the seam edges, to

change the resistance of the circuit. The pressure of the welding electrode on thetube also determines the resistance of the welding circuit and it has been the practice to raise or lower the.- electrode to 'provide the desired contact pressure on the: tube. It is obvious that almost superhuman skill is required to" manually adjust the welding voltage and the pressure on the seamedges so 35 as to produce a' satisfactoryweld at all times.

A further variable is the speed of travel of the.

tube being welded. Obviously, the greater the speed of travel for a given current, the smaller the amount of currenttraversing a unit section oilthe/ 40 s'eam'edgeand the lower the temperature attained thereby. 'When anoperator is called upon to control the speed of pipe travel as'well as the other variables, 'thetask amounts to a practical imposs'ibility. It is'an object of this invention to pro- 34 vide a system of control for an electric welder nsuch 'that all the variables will be automatically controlled continuously in accordance with'cer- .tain predetermined conditions. Only by such means can all the variables be properly controlled so so as to producefth desired quality or product.

x accordance with my invention, I employ r'welding transformers which rotate with the electrode. High voltage current supplielrto the pri- 1 mary windings of the welding transformersfrom 59 Claims.

voltage generated by one or both of said generators so that the resultant voltage applied to the primary windings of the transformers may bva ried at wili or automatically with the desired efiect on the secondary or welding voltage. Automatic voltage regulating means similar to that dwcribed and claimed in my copending application, Serial No. 574,507, filed November 12, 1931, for Control system for electric welder, since matured into Pat- I ent No. 1,967,198, dated July 17, i934, is employed to maintain the desired constant welding voltage. The application of the high voltage to the transformer windings is controlled in accordance with the movement of pipe through the welder. I also provide means responsive to the speed of the welder for controlling the application oi. voltage in case the welder operates at speeds higher or lower than the optimum speed for a predetermined period of time. The welding current and the electrode speed are properly coordinated by automatic means to. insure that each unit section oftube seam is traversed by the amount of current required to raise it to the welding temperature. Additional features such as voltage regulation and protection against various classes of contingencies, such as power failure and the like, are provided.

In order to control the current across the tube seam, I provide a means for varying the pressure of the electrode on the tube, as well as the pressure between the edges of the latter. These means are controlled jointly by the speedof the pipe and the magnitude of the welding current, so that the resistance of the welding circuit is always adjusted to the existing welding current and electrodespeed. Means for discontinuing the welding current when the pipe leaves the welder are also included. p As an alternative method of controlling the yoltage across the welding electrode, 1 have invented means to varying the phase angle between. the twogenerators connected in series to supply the welding cin'rent to the-electrode. I accom- -plish this by shifting the stators ot-the two generators in opposite directionsfso that there 45 sultant voltage is increased or decreased. 7. The 7 same principle is; employed in cutting oi! the welding current just before the tubepasses out of thewelder; e v

Fbr a full and complete understanding or the invention, reference is made to the accompanying drawingsiillustrating a present preferred em? bodiment. Ipthedrawings:--

' Figure 1 is a schematic circuit diagram illusb5 t generators in series; arrange to -vary the trating the various element-sot the systeminsuch position that the circuits are simplified to the greatest possible extent; V

Figure 2 is a portion of a complete circuit diagram showing the various elements diagrammatically in the relative positions which they actually occupy: I

Figure 3 is another portion of the complete circuit;

Figure 4 completes the showing of the circuit diagram in full; a

Figure 5 is a sectional view of a detail; 7 Figure 6. is a partial diagrammatic view illustrating a modification of one element of 'the invention; V

Figure 7 is a partial diagram showing a further modification; w Figure 8 is'a' schematic diagram of the mechanism employed to vary the phase,relation betweien the voltages of the two welding generators; an Figure 9 is a sectional view through one of the generators showing the stator shifting mechamsm.

- Referring in detail to. the drawings, the system of my invention is, adapted to supply energy to a welder l0 comprising an electrode II and transformer groups I? located on either side on a shaft I3 which supports the electrode and transformers for rotation. Bearings it for the shaft are ad is of the watt hour meter type having a voltage justable vertically by adjusting screws 15 for shifting the 'rotating apparatus. The shaft I Bis driven by a motor it through a gear I1 and a pinion l8. Adjustable side pressure rolls IQ -are mounted below the electrode and a bottom roll 20 is positioned therebetween for receiving a formed tube 2! and guiding it through the welding j throat constituted thereby, together with the electrade I I." This type of Welder is described and is a variable voltage generator, although both generators may have means for varying the voltage, if

desired. The voltage of the generator 25 may be varied in magnitude or in phase relative to that of the generator 26 so that the voltage of the two machines'is cumulative or in opposition. In otherf words, the generator 25 may be made to buck or boost the generator 26 sothat practically any desired voltage may be applied to the welding transformers/I prefer to have the generators connected whether for bucking orboosting so as'to employ a stifi field-excitation .with consequent reduction in the eifect of armature reaction The generators '25 and 26 are mounted on a shaft 21 which is directly connected to a synchronous motor 28. The motor 28 draws its energy from a main supplycircu'it 29. In addition to the generators 25 and 25, and the motor 28, the

shaft 21 also drives an excitergenerator 30 adapted to. generate a constant voltage, and an exciter generator 3| for generating a variable voltage. A

constant'voltage alternating current generator 32 is also mounted on the shaft for a purpose which will be explained later. The generator 38, of

an windings of the'transiormers'. I

ator 3G is driven by the motor 86 through' any Preferably, the generator is provided with a contact arm M which carries course, is adapted to supply direct current to the speed, which is usually the independent variable, I employ alternating current generators and provide. means for'driving said generators at speeds proportional to the welding currentand the electrode speed, respectively. Generators 33 and 3; have distributed stator'and rotor windings. The excitation for the-stator windings is 'obtained from thecircuit 29 through conductors J 35. As is well known, generators of the type mentioned deliver energy from the rotor when 'operated above synchronous speed. Belowsynchronous speed the rotors absorb energy ifany is available. In other words,- the output from or tween the welding current and the electrode input to the generator depends upon whether'the generator is operating above or below synchronous speed and if so, to yhat extent. This is the ordinary induction generator principle in which the excitation is furnished by an alternating current.

The generator 33 is driven by a motor 36 which winding 36' and a current winding 37. As in the case of the ordinary watt hour meter, the speed of the motor 36 is proportional to the product of the; voltage applied to the voltage winding and the current traversing the current winding.

The voltage winding 36' is energized by the cona speed proportional to the current traversing the primary windings of the transformers. Subst antially a constant relation exists, of course,

between the current in the primary and second- The generconvenient drive, as an example of which I have shown an adjustable belt 39 traveling on cone pulleys to permit variation in the relative speeds of the motor i6 and the generator 34. A commercial form of this device is known as the Reeves drive.

The speeds of the generators 33 and 36 are compared by an electrical differential relay lii, which is-nothing'more than an induction motor with a wound rotor. The relay should be designed, however, to operate at stand-still, since the rotor has only a limited movement for the purpose of" making or breaking contacts. The stator of the relay GE is connected to the slip rings of .the generator 33. The rotor winding of the relay to is conneoted to the slip rings of .the generator 3&1. The torque on the rotor of the relay ii), of course, depends upon the direction of the flow of power therethrough. If

the generator 33 tends to send power through the relay 6B which is, of course, a transformer, to the generator 3 3 acting as a motor, the relay operates in one direction'. If the flow of power is in the reverse direction, the tor ue on the rotor of the relay is similarly reverse The relay till moving contacts 62, :33 and M.

The output of the generators 33 and 36 is also u 1,996,902 utilized to control thevertical adjustment of the , electrode H and the pressure exerted by the side pressure rolls l8. Vertical adjustment of ,the

-. electrode II is effected by the shaft 45 provided.

with worms 46 engaging worm wheels 41. The

worm wheels 41 have threaded bores for receivnets of said clutches being indicated diagrammatically at 52 and 53. The-clutch magnets 52' and 53 are under the control of a relay 54, which is controlled in turn by a manual switch 55.

The motor 48 has stator and rotor windings 56 and 51 connected to the generators 33 and I 34, respectively. The motor 48, therefore, operates similarly to the relay 40 the direction and control current to various auxiliary devices through a control bus 6|. The clutch magnet 52 is normallyenergizd from this circuit since its lower terminal is connected directly to'the bus 6| and its upper terminal is connected to the speeds of the generators 33 and 34.

bus 62-through the lower, normally closed, or back contact of the relay 54. The motor 48 thus operates to raise or lower the electrode II to control the contact pressure on the tube being welded in accordance with the comparative The motor 49 permits the electrode to,be initially adjusted under manual control. In order for the motor 48 to adjust the electrode,' however, the manual switch 55 must be closed to energize the relay 54 so that its upper, normally open, or front contact will be closed to energize the clutch magnet 53 and deenergize the magnet 52.

A regulator 6 la provides automatic regulation for the field winding of the variable volt- .age exciter-generator 3| and consequently for the voltage of generator 25. The field winding is indicated at 62 and isnormalfy connected in series with a resistor 63 across the armature of the generator 8|. Conductors 64 comprise a circuit extending from-the terminals of the resistor 53,

a to main contacts 65 of the regulator Gla. When In addition toregulating the pressure of the electrode on the tube, and the volta'geof the'welding circuit, I alsoncontrol the pressure of the side rollslfi'engaging the tubeby automatic means.

' These rolls'are mounted in adjustablehous ings 69 carried on adjusting screws 16. The screws 18 traverse. a threaded bore in a sleeve" carried in supporting brackets 12; Agear 13' keyed to the sleeve 1| which is rotatable in the bracket 12 permits adjustment of the pressure. of the side rolls by means of a motor driving a shaft 15 provided with'pinions 18 meshing with the gears, 13. The

motor 14 is similar to the motor .48 and its stator and rotor windings 11 and 18 are connected by circuits 19 and 88 to the generators 33 and 34.

The side pressure rolls are thus adjusted to incream the pressure they exert on the tube when thespeedof pipe travel, as indicated by the frequency of the generator 33 increases. The motors 43 and 14, of course, instead of being connected directly to the generators 33 and 34, may be concontrolled motor similar to that shown at 49 may also be provided for adjusting the side pressure rolls.

The remainder of the control system comprises principally auxiliary devices such as relays, contactors, and the like, which are standard equipment and therefore require no detailed descrip- .t'rolled by relays similar to relay 40. A manually tion. The operation'of these devices the desired sequence will therefore be explained in the general description of the operation of the system about to be given. Thisdescription may be read either with reference to the complete circuit diagram of Figures 2 throughd, or with reference to the schematic diagram of Figure 1. In the latter, the relay contactsare designated by the number of the relay and a superscript indicating the position of the contact on the relay, counting down from the top, where the contact isshown apart from its relay. Generator fieldsare indicated in Figure 1 by F added.

Starting and control circuits-for the motor 28 and the motor |6 have not been illustrated since they are already well known and are not part of V the present invention. Normally, the system will operate on constant frequency but the speed of the electrode motor will be variable under manual control to provide a high quality of product.

Theentire automatic operation of the system is under the control of a starting push button 8|. Until this push button is operated, there is no current available at the buses 6| and 62 for operating the automatic devices When the push but- -ton 8| is operated, arelay 82 is connected directly across the armature of the generator 30 and operates to close its front contacts. from; contact completes a locking, circuit for the reiay through a stop push button switch 83which is normally closed. The lower contact of the relay completes thecircuit from the armature of the generator 38 to the control bus 62- through the the number of the generator with an The upper contacts of power failure relays 84 which are normally closed. 7 V

A rotary switch 85 is positioned in the path of .or other means to delay opening thereof on de energizing of its winding. The closing of the bottom contact of the relay 86 connects the differential coil 68 of ,the regulator 6|a to they con-' 135ithereby. The closing of the upper contact of the tact 42-of the relay 48 g for subsequent control relay 86 completes a circuit from the b us 6| through the welder switch 35, thehpper contact of the relay 86 to the winding of arelay 81 and thenceto the bus 62. The switch 85 is closed for an instant only, butthe 'advancingtube imme- A 98 of which are normally in engagement "so-that the contact 89 engages a contact 8|; The flag switch 8' is heldin operative position as long as entering the welder so hat the tube diately operates a flag switch 88, contacts 83 and M.

4?: the pipe is traversing the welder. The relay 81 is thus energized during that period. v

.When the relay 8'! is energized, its upper front contact completes a circuit for a contactor 92. 5 This contactor operates the contacts 93 and 94 which connect the field windings oi the generator 25 across the variable voltagegenerator l and the field winding of the generator'26 across the fieldwinding-of the generator '30. The two top contacts of the relay 81 shunt the field windings of the generators25 and 25 when the relay is'deenergized. The top contact of this relay is de signed to open last.

A relay-95 is adapted tobe energizedcontinuously. Before the tube enters thewelder, this relay is energized by a circuit under the control oft-he contacts 89 and 9B of the welder switch 88,

which are normally closed. when a pipe enters the welder so that these contacts are opened, the a relay 95 is under the control of contacts 96, which are closed as long as the relay till occupies the neutral position but which are opened when the relay moves in either direction. Both the relays t5 and 8'11 are slow releasing relays and have dashpots or other means for this purpose. The relay '95 controls'the excitation of the generators 25 and 2a.; The circuit for the contactor'92 includes the top contact of the relay 95so that if the relay 95 is deenergized, excitation for the generatorfieldwindings is .cut oil. The relay 95 is designed in any convenient manner so the top contact is the last to open. The lower contacts of the relay 95 cooperate with the corresponding contacts of the relay 8! to shunt resistors 91 and 98, which are connected inseries with the field "winding scribed in the foregoing, welding, current begins to fiow through the tube. A relay 9,9 is connected to a current transformer 99a in the circuit between the winding 37 and the motor 85 and the transformer 38, The relay as is therefore energized as soon as a predetermined current flows to the electrode. The operation of the relay 9? closes a circuit for a contactor 3%.. The contactor 8% closes contacts 800 connecting the windings 5G, 57, TH and 78 of the motors lfi and it to the generators 3t and 36, so that the motors operate under the continuous control of the generators as long as there is any difierence in the frequency of the latter. If the generators 3 and 3d operate at the same speed, the motors 38 and M remain stationary. v \fi a While the tube is passing through the welder, the voltage of the exciter 3! is controlled by the regulator em and the relay it. Under normal; conditions, the generators 38 and 36 operate at the same speed, the speed of the generator 3 3 being adjusted by means of the Reeves drive to correspond ,with that attained by the motor 35 when the generators are supplying normal weld ing current. The magnetizing coil 6? of the regulator Ma is connected directly across. the

buses GI and 62. The difierential coil 88 will be connected across thesame circuit when the contact 52 of the relay 3B is closed. Thecontact d2 of the relay 60 will be closed whenever the current supplied to the welder decreases so that the speed of the generator 33 drops. Under these conditions, the energization of the difletential 1,996,902 V coil as neutralizes the efiect a the magnetizing coil 81 andpermits the spring 66 to close the regulator contact 65. The resistor63 in series with the field ofthe'exciter generator Si is r shuntedso that the excitation of the generator is increased. The result, of course, is that the excitation supplied to they generator 25 is increased.

As soon as the welding current returns to itsnormal value, the generator 33 speeds up, the relay at opens its contact $2 to deenergize the coil since the latter'is a slow opening relay, it does not atonce open its contacts. Its contacts open only after a predetermined time after it has beende energized and this time may be adjusted so that during ordinary operations the relay will not drop out. The contactdt of the relay ell controls signal lamps WI andlilZ-to indicate to the operator the conditions under which the welder is operating.

If the relay ifl maintains the contactshtdopen" for the predetermined. length of time, due to a difierence between the speeds of the generators 33 and St, the relay 9 5 will finally drop out and deenergize the contactor 92 so that the contacts 93 and 95 will open to-disconnect the-generator field windingsfrom their source of excitation. The welding current is thereby cut 'o'fi;

' If normal conditionsprevail until the pipe is completely welded, the passage of the completed tube from the welder will release the fiag switch dt-so that itcloses its contacts 89 and 9t and opens the contact'si. This deenergizes the relay 8? but the latter is a slow operating relay'so that it does .notimmediately drop out. The relay 8? is set to drop out Just before the trailing end of the tube leaves the electrode. When it finally opens, the shunts are removed'from the resistors in series with the fields, the field windings are .shunted, and the field contactor 92 is then deenergized to open the field circuits.

, As soon as the generator fields are deenergized, current stops flowing in the'weldir g circuit and the generator st slows down. This tends to operate the relay to, but'the opening of the welder switch at deenergizes the relay 8% and'prevents the relay 36 from controlling theregulator Ma.

When welding current ceases, the relay 99 is deenergized and the contactor we opens its contacts to disconnect the motors it and ill from the generators 33 and M. V I

The relay 95 has its time delay means adjusted so that it will not open between the cessation .of the welding currentand the closing of the con-' tacts 89 and 90 which maintain energization of the relay winding.

gized at all t es unless some abnormal condition arises and continues for a definite length of time.

In such case,the relay drops open and deenergizes the generator field windings. The object The relay 95'is thus enerlimiting resistors are connected in series thereand the series resistors are shunted. The entire system is then under the control of the relay 40 imtil the tube has passed entirely through the welder. A reversing switch RS permits reversal of the field25F;

Figure 6 illustrates the means for maintaining the generator 33 is driven from the electrode motor I6 by means of a magnetic clutch I02 which is engagcdas soon as the welding current ceases.

p Arelayvll3 controls the clutch I02. This arrange:

ment permits the relay 40 to maintain its neutral position even though the welding current has been discontinued. The clutch I02 will be designed so that, when engaged, there will be a predetermined relation between; the rotors of the generators 33 Figure Tshows another method of accomplish ing a similar result except that electrical means are employed instead of mechanical means. figure also shows further the scheme of connections for operating the motors 48 and 14. In

transformer. The converter I05 is driven by a synchronous motor I06. T

A generator I 01 is driven by the electrode motor 55. A synchronous motor I08'is adapted to be driven by the generator I01. when a relay I09 is decnergized by cessation of the welding cur rent. In' other words, the generator 33 is driven by the motor I01 at a speed proportional to the welding current as long as that current persists. When that current ceases, the synchronous motor I00, driven by the generator. I 01, drives the gen erator 33 and the changeover is automatically accomplished by the relay I00. The scheme of stator and rotor connections for the motors 48' and 1| is clearly shownin Figure '1. According to this scheme, the stator windings ofhoth motors are connected to the generator 33 and rotor windings of both motors are connected to the windings of the generators 25 and 26 are connected in series with the generator 3| through a' carbonpile rheostat I I0. The stators of the generators 25 and 20 are adapted for rotation under the control of worm drives III operated by reversing motors IE2. The motors II2 are controlled by a contact I I3 on ashaft I I I which alsooprates the rheostat. H0. The shaft I'Ilis actuated by a special type of synchronous motor II5 having a rotor which rotates on the shaft. A threaded relation between theshatt and the rotor is provided so that as long as the two are driven in synchronism, there is no axial movement of the shaft I I4. The shaft of the machine I I5 is driven by a motor H which is driven at a speed proportional to the current flowing in the welding circuit 22. The stator winding of the machine and 34 whereby they will operate in phase.

reverse the stator shift.

H5 is energized by the output of the generator 30 driven by the electrode motor, as in Figure 7 and drives the rotor at synchronous speed. The motor -I I6 is energized by the output of a pair of rectifier-s H1. The rectifier output is controlled by the current passing throughthe circuit 22, by means of transformers H8 and I I9.

When the'motor IIB accelerates in response to increased welding current so that there is anaxial movement of the shaft I I4, the contact H3 energizes the forward and reverse fild windings of the motors II2 to cause shifting of the stators of the generators 25 and 26 is opposite directions, to increase the phase angle between the voltages thereof so that the resultant voltage will be decreased and the welding current similarly reduced. As the welding current decreases, the reverse operation takes place and an increased voltage is applied to the welding circuit. In either case, the restoration of the desired welding current terminates the adjustment of the generator stators. The carbon-pile rheostat is operated by the shaft I I4 in a well known manner to vary the encitation of the generator fields similarly. V

In order to reduce the welding voltage before the end of the tube passes out of the welding throat, I provide a flag switch I20 adapted to be closed by the leading end of the tube while the trailing end is still in the welder. The switch I20 completes a circuit for the motors II2 to shift the stators of the generators 25 and 26 so that the welding voltage will be reduced substantially to' zero; A normally closed limit switch,

indicated diagrammatically at I21, over-travel of the generator" stators. welding current is reduced to zero by changing the'phase relations of the generator voltages, there would be -a tendency for the contact H3 to To prevent this, it is necessary to drive the rotor of the motor H6 by the synchronous motor I08, as shown in Figure 7, which operates in synchronism with the generator I01, driven by the electrode motor. The energization of the motor I08 is controlled by the relay I09 as in Figure 7. This prevents the operation of the contact I I3 to restore the welding voltage as it ordinarily would do when the welding current decreased. r

. When the next tube'enters the welder, therefore, the generator stators are in a position or minimum voltage. A switch I22, similar to that shown at 85, operates as the next pipe enters the welder to energize momentarily the reverse field windings of the motors I I2 to'start the generator stators back toward normal position. This initiates the building up of the welding voltage prevents and a relay I23a-operates simultaneously to deenergize the field of motor I08 and generator I01 so that subsequent operation of the stator shifting mechanism is under the control of the contact II3 which is responsive, however, to the welding current andelectrode speed. The relay I231; is an adjustable, slow operating relay and is energized only for an instant. The initiation of welding current causes the operation of the relay I09 to maintain the field circuits of generator I01 As the and motor 108 open. As soon as the succeeding shifting mechanism is again placed under the control of the electrode speed and the welding current, as beiore.

Figure 9 illustrates one form which the stator shifting mechanism may take, together with an alternative arrangement for reducing the welding voltage as the tube is about to leave the welder. Figure 9 shows the generator-25 having its stator rotatably positioned on bearings I23 in a base I23. The motor I I2 operates aworm I24 for shifting tlfe stator of the generator 25 by means of worm teeth formed therein. The worm I26 is connected to the motor II2 through a universal joint I25 and'a, spring I26 normally urges the worm into engagement with the worm teeth. The outer end of the worm shaft is carried in a bearing block I21 slidable in arcuate guides I21 formed in the base. An air cylinder I 28 when under pressure, operates to pull the worm shaft out of engagement with the worm teeth so that the generator stator is free for rotation independent thereof. An air cylinder I29 operates to shift 'the stator practically instantaneously to the position in which the welding voltage is reduced substantially to zero. A spring I30 cushions the movement of the piston in the cylinder I29 and also serves to return the generator to normal position. A flag switch I26, corresponding with that shown at are, operates to control a valve I3I admitting pressure to the cylinders I23 and I29.

In operation, the apparatus shown in Figure 9 is similar to that of Figure 8. When the flag switch I26 is closed, the valve I3I admits fluid to the cylinders I28 and I29. The piston in the cylinder I28 withdraws the worm shaft I25 from engagement with the worm teeth on the stator of the generator 25. The piston in the cylinder I29 instantaneously shifts the stator of the generator .25 to the position in which the welding voltageis produces the minimum voltage until the next succeeding tube enters the welder, by the use of suitable control switches.

It will be apparent from the foregoing description that my invention provides a systemior the control of generators in a welding system so that the desired results are obtained automatically at -all times. Among the objects accomplished and voltage across the electrodeis built up as the tube enters the welder and correspondingly re-.

duced to zero as the tube leaves the welder. All is thus avoided If the welder operates "abeye or below normal speed, or if the .welding current is -maintained above or belownorinal 'value for a predetermined time, the welding cur-.

rent will be shut off. The correlation of welding current and'electrode speed maintains a constant properly compensated for by adjusting the weld ing current in the proper direction. If the tube welding heatat the edges of the tube seam. Any

variation in flow of current or electrode speed is diameter varies, the different pressure exerted by this condition, The contact pressure of the welding'electrode is likewise adjusted and wear of the electroderis automatically compensated for by vertical adjustment thereof. The electricalthe advantages obtained are the following. The

differential relay can be employed as a signal to the operator, as well as an automatic means correcting'undesirable conditions.

Instead of adjusting the voltage of one generator, I can use two constant voltage generators and vary the phase angle therebetween in order to obtain the proper welding voltage. This lsystern is also capable of automatic actuation and has the advantage that the efiect of armature reaction is not so pronounced where a good strong field is employed in both generators instead of a full field in one and a weak field in the other.

The control of the welder voltage by varying the phase relations between the voltages of the two welding generators offers many advantages. The system is simple and efiective. None of the main circuits need be opened and the control mechanism is relatively inexpensive.

Although I have illustrated and described herein but a few of the possibilities'of the inven-' tion, it will beapparent that it may be practiced otherwise and by the use of other apparatus. Any such changes, however, which do not depart from the spirit of the invention are intended to be contemplated within the scope of the appended claims.

1. An electric energy supply system for welding apparatus including an electrode, comprising transformershaving their secondary windings connected to said electrode, a pair of generators connected in series to the primary windings of the transformers, common excitation supplying means for said generators, and means for varying the resultant of the voltages of said generators.

2. In a welding apparatus, an electrode and side pressure rolls, means for adjusting the electrode and side pressure rolls relative to the work, means for automatically actuating said adjusting means in accordance with the speed of the electrode and the welding current, and means actuated by movement of the work for rendering the pressure regulating means ineffective when the work passes out of the welder.

. as In an electric welder, the combination with anelectrode, transformers for supplying current thereto, of a generator for supplying current to the transformers, said generator having a movable stator, and means for shifting the stator to vary the voltage applied to the transformers in accordance with the magnitude of the welding current and the speed of-the electrode.

for

4. In a welding system, the combination with a pair of generators having movable stators for jointly supplying welding current to an electrode, of means automatically responsive to the speed of the electrode and the current supplied thereto the phase relatipn of the voltages thereof.

connected in series for supp 5. In an electric welding system, an electrode, transformerstherefor, and a pair of generators 'ng current to said ransformers, said generator having movable stators and means for automatically controlling the excitation of said generators, means for shifting the stators of said generators to vary the resultant voltage applied to the transformers, and means responsive to the electrode speed and the welding current foractuating said excitation controlling and stator shifting means.

-6. "Iii a welder, the combination with an elec trode, of generators connected in series for supplying current thereto, and means for varying the relation between the generators-for varying the voltage across said electrode.

'1. In a welder, a rotary electrode, a variable 'voltage generator for supplying current to the electrode, vertical adjusting for the electrode, pressure rolls and'adiusting means therefor, and means responsive jointly to the speed of the electrode and the current supplied tlier'eto for controlling the operation of saidadjusting means for the" electrode and pressure rolls. a

8. In a welder, the combination with a rotary electrode, a variable voltage generator for supplying current thereto, a regulator for control ling the generator voltage, and means for vertically adjusting the electrode, of a relay for ren-. dering said regulator ineffective, and me actuating said adjusting means and said relay, said last mentioned means being responsive to the speedof'said electrode and the current supplied thereto.

9. In a welder, a rotary electrode, a generator supplying current thereto, a regulator for' controlling the voltage of the generator and a relay including means responsive to the irequencies'of the last mentioned generators.

10. In a welder, an electrode, side pressure rolls, means for adjusting the electrode and means for adjusting the side pressure rolls to and from the work, means responsive to the electrode speed and electrode current for operatingsaid adjusting means, and means responsive to the electrode w Y generators connected in series-and having their current for rendering said adjusting means effective when current is being supplied to the electrode.

11. In awlden-a work-engaging roll, means for adjusting the roll relative to the work, manually controlled operating means for the adjusting means, means responsive to the currentsupplied to the work eflective to operate the adjusting means, and releasable connections between said operating means, respectively, and said adjusting means.

12. In a control system for an electric welder including an electrode, a driving motor and a supply generator therefor, side pressure rolls and means for adjusting said rolls laterally and said electrode vertically, a motor energized in ancordance with electrode current, generators driv-' en by said motors, and motors controlled jointly by said last mentioned generatorsfor effecting operation of said adjusting means.

13. Thcombination with a welder electrode, a

' generator for supplying current thereto, a field fore the workleaves the welder.

from the work, a motor for driving it, a .generator for supplying current thereto, and pressure rolls adjustable to and from the work, motors for adjusting said electrode-and pressurerolls, and

means for varying the excitation of said generator and said adjustingmotors comprising a generator driven by said electrode motor, a second generator having means" for driving it at a speed proportional to the electrode current, and means for-operating said last-mentionedgenerators synchronously when said, electrode current ceases.

1 6, In a welder having an electrode, a driving motor therefor, a generator for supplying electrode current; pressure rolls, said electrode and rolls being adjustable to'and from the. work,

and means for simultaneously varying the gen? erator excitation and the adjustmentof the electrode and pressure rolls comprising a generator .driven by said motor, a-second generator, a frequency converter anda driving motor for operating said second'generator at a speed proportional to electrode current, and a relay andad- .justing means forthe electrode and pressure rolls responsive to asynchronism of said two last-mentioned generator'sand means for. operating said generators synchronously on cessation of said electrode current. A

17.In an electric welding system, the method of terminating the flow of welding current which includes the step of changing; the phase-relations of thecomponents of the welding voltage.

18 In a,welding system, the method. of volt-' age control which includes the steps of varying the phase relations of the compcnents of the' phase relations of the generated voltages. 1

20. 111 a welder, the combination with an electrode, generators for supplying 'current to the electrode, of means for varying the current supthe weldingopration, and eiiecting a ing the stators of said generators to vary the plied in accordance with the electrode speed and 4 the magnitude of the current, said means including a'direct current motor, and means for energizing said motorwith a directcurrent proportional to the welding current.

21. In a welder, a rotary electrode, means for supplying current to the electrode, pressure rolls, means for. adjusting the electrode and rolls to and from the work, and means responsive jointly to the speed of the electrode, and the current supplied thereto for controlling the operation of said adjusting means for the electrode and the pressure rolls. v

22. In a welder having an electrode, a current supply systemtherefor, pressure rolls, the electrode and rolls being adjustable to and from the 'work, means for simultaneously controlling the ourrent supply, and the electrode and pressure roll adjustment comprising a generator, means for driving it at a speed proportional to that of the electrode, a second generator, and driving means for operating saidsecond generator at a speed proportional to electrode current, adjusting means for the electrode and pressure rolls, and

relay responsive to asynchronism of said two last-mentioned generators for controlling said adjusting means, and means for operating said generators synchronously on cessation of said electrode current. V 7

' sponsive to the current traversing said contact roll for automatically adjusting at least one of the rolls to vary the size 'of the throat and the pressure exerted on the work thereby.

25. In an electric welder, the combination with V an electrode, a transformer for supplying current thereto, of a generator for supplying'current to the transformer, said generator having a movable stator, and means for shifting the stator to vary the current supplied to the work in accordance with the speed of the work.

26. In a welding machine, a supply system therefor, electrode and pressure rolls embracing the work, means for adjusting said electrode and pressure rolls automatically toward and away from the work while thework is progressively and longitudinally moving through the machine 'to effect a uniform weld, and means for rendering said adjusting meansinoperative when the work leaves the welding machine.

27. In awelder, a rotary electrode, a system for supplying current thereto, a regulator for varying the supply voltageof the system, and means for biasing the regulator comprising a pair of generators driven respectively at speeds proportional to the electrode current and speed, and a relay responsive to asynchronism of said generators.

28. In a pipe welding: machine, an adjustable electrodeand adjustable side pressure rolls embracing the tube to be welded, and means for ad- ,justing said electrode and side pressure rolls,

comprising a pair of generators driven at speeds proportional to the electrode current and speed, and a relay responsive to asynchronism of said generators. 1 a

29. The. combination with a welder electrode, a generator for supplying current thereto, and a field winding for said generator, of means actuatedby movement of the work relative to the electrode for establishing or terminating current in said field winding, and means responsive to the speed of the work for further controlling the current in said winding. a 30. In an-electric welder, the combination with an electrode, of a plurality of sources connected in series for jointly supplying current thereto including a generator having a movable yoke, and

means for shifting the yoke to vary the vector.

relation of the voltages of said sources in -'accord-.

ance withthe magnitudeof the welding current and the speed of the electrode. 1

31. In an electric welder, the combination with an electrode, of a plurality of sources-connected in series for jointly supplying current thereto including a generator having a movable yoke, and means for shifting the yoke to vary the vector relation of the voltages of said sources in accordance with the magnitude of the welding current.

32. In an electric welder, the combination with an electrode, of a plu'rality of sources connected in series for. jointly supplying current thereto including a generator having'a movable yoke, and means for shifting theyoke to vary the ing-current supply source, a direct-current motor, means for generating and supplying 'to'said motor continuously a direct current proportional at all times tothe alternating current delivered by said source, and meansactuated by said motor for controlling the voltage of said source.

35. The combination with a welding electrode, a generator for supplying current thereto, a regulator for the generator, and a relay controlling the regulator, of a circuit closed by movement of the work toward the welder,:and means controlled by said circuit for rendering said relay eifective to control said regulator.

36. In a welding apparatus, an electrode for supplying current to moving, opposed seam edges, and pressure rolls for forcing said edges together, and means for adjusting said pressure rolls to and from the -work, means responsive to the speed of movement of said edges, and means'actuated thereby for operating said adjusting 37. In a welding apparatus, an electrode for supplying current to moving, opposed seam edges, and pressure rolls for forcing said edges together, and 'means for adjusting said pressure rolls to and from the work, means responsive to the magnitude of the currenttraversing the electrode, and means actuated thereby for operating said adjusting means.

38. 'In'a welding apparatus, an electrode for supplying current to moving, opposed seam edges, and pressure rolls forforcing said edges together, and means for adjusting said pressure rolls to and from the work, means responsive, to the speed of movement of said edges, means respons'ive to e magnitude of the current supplied by said electrode, and means controlled jointly by said two last-mentioned means for operating said adjusting means.

39. In awelding apparatus, an

electrode 'side pressure rolls, means for adjusting the elecing means responsive tothe welding current and means actuated by movement of the. work for rendering the pressure regulating means ineiiective when the work passes out of the welder.

40. In an electric welding system, an electrode, transformers therefor, and a pair of generators connected in series for supplying current to said transformers, said generators having movable stators andmeans for automatically controlling theexcitation of said generators, means for shifting the stators of said generators for varying the said voltage applied the transformers, and means responsive to the'lwelding current for actuating said excitation controlling and stator shifting means.

41. The combination with a welder electrode, a generator for supplying current thereto, a field winding for said generator and means actuated plied thereto for further controlling-the energization of said winding.

'aooaooe 42. In a welder, the combination with. an electrode, a generator for supplying current to the electrode, of means responsiveto the tude oi the current for controlling the generator, said means including a direct current motor and means for energizing said motor with a direct current proportional to the welding current.

43. In a welder, the combination with a rotary electrode, a variable voltage generator for supcontrolling the voltage of the generator, and a relay for rendering the regulator effective, pressure rolls and lateral adjusting means'theretor, means for adjusting said electrode vertically, motors for operating said adjusting means, and

means for controlling said relay and motors including a generator driven at a speed proportional to the electrode current.

45. In a welder, an electrode, side pressure rolls, means for adjusting the electrode and means for adjusting the side pressure rolls to and from the work, means responsive to the electrode current for operating said adjusting means, and means responsive to the electrode current for rendering said adjusting means effective, when current is being supplied to the electrode.

46. In a welder, a rotary electrode, a system for supplying current thereto, a regulator tor varying the supply voltage or the system, and

means 101' biasing the regulator comprising a generator driven at aspeed proportional to the electrode current and a relay responsive to the freouencyoi said generator.

4'7. In a welding apparatus, an electrode and side pressure rolls, means for adjmting the electrode and the side pressure rolls relative to the work, means for automatically actuating said adjusting means, said actuating means being responsive to the speed or the work, and means actuated by movement of the work for rendering the pressure regulating means inefiective when the work passes out of the welder.

, generator for supplying current thereto, a field winding for said generator, means actuated by movement of the work relative to the electrode for varying the energization of said winding, and means responsive to the electrode speed for further controlling the energization of said winding.

50. in a control system for a welder including an electrode and a generator therefor, a relay responsive to electrode speed, and means conmum by said relay and operative only alter a predetermined time, for rendering the generator inefiective.

52. In a welder, the combination. with an electrode, a generator for supplying currenttc the electrode, of means responsive to the electrode speed for controlling said sin-rent, said means including a synchronous motor and means for energizing said motor with a frequency proportional to the electrode speed.

52. In a welder, the-combination with a rotary electrode, a variable voltage generator for supplying current thereto, a. regulator tor controlling the generator voltage, means for vertically adjusting the electrode, of a relay for rendering said regulator ineffective, means for actuating said adjusting means and said relay, said actuating means being responsive to the electrode speed.

53. In a welder, arotary' electrode, a generator for supplying current thereto, a regulator for con-- trolling the voltage of the generator, and a relay for rendering the regulator effective, pressure rolls and lateral adjusting means therefor, means for adjusting said electrode vertically,.motors for operating said adjusting means, and means for controlling said relay and motors including a generator driven at a speed proportional to the electrode 54. In a welder, an electrode, side pressure rolls, means for adjusting the side pressure rolls to'and from the work, means responsive to the electrode speed for operating said adjusting means, and means responsive to-the electrode current for rendering said adjusting means eiiective when current is being supplied tothe electrode.

55. In a welder, a rotary electrode,-. means for supplying current to the electrode, pressure rolls, means for adjusting the electrode and rolls to and from the work, and means responsive to the elcctrode speed for controlling the operation of said adjusting means 101' the electrode and the pressure rolls.

56. In a welder, a rotary electrode, a system for supplying current thereto, a regulator for varying the supply of voltageto the system, and means for biasing the regulator comprising a generator driven at a speed proportional to the electrode speed and a relay responsive to the frequency of said generator.

57. In an electric welding system, the method of initiating the flow of welding current which includes the step of changing the phase relations of the components of the welding voltage.

58. An electric'welding machine comprising a contact roll and work-engaging rolls cooperating therewith to form a welding throat, means for feeding to said throat the material to be welded, and means responsive to the resistance of the welding circuit including said contact roll and the work, for automatically adjusting at least one-oi said rolls to vary the pressure on the work.

59. An electric welding machine comprising a contact. roll and work-engaging rolls cooperating therewith to form a welding throat, means for feeding to said throat the material to be welded. and means responsive to the pressure exerted or the work by said throat for adjusting at least on: of said rolls to vary the size o neat so maintain a constant pressure on work.

@APUTQ. 

